Crash box component holder

ABSTRACT

An energy dissipation assembly is provided for dissipating energy between a vehicle component and a vehicle sheet metal member. The assembly includes a collapsible crash box forming a central aperture therethrough for receiving the vehicle component. The collapsible crash box includes a plurality of collapsible levels oriented concentrically with respect to the central aperture. A sufficient impact against the component causes collapse of the plurality of levels between the component and the sheet metal member, thereby dissipating energy of the impact.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional application Ser.No. 60/098,857, which was filed on Sep. 2, 1998.

TECHNICAL FIELD

This invention relates to a collapsible crash box for dissipating energybetween a coat hook and a vehicle roof.

BACKGROUND ART

It is know to mount various trim components, including conventional coathooks, to a roof bracket of a motor vehicle interior. It is required bythe Federal Motor Vehicle Safety Standard 201 that these components meetor exceed the head impact criteria values designated thereby. The priorart includes examples of components that can be attached to a roofbracket of a motor vehicle interior. However, these components aregenerally formed from one piece, do not provide easily changeable impactand deformation characteristics, and further, lack the stability, loadbearing, and cosmetic characteristics desired in such components.Further, the components in the prior art do not conform readily to thecontour of the headliner material of the motor vehicle.

DISCLOSURE OF INVENTION

According to the invention, a component mounting bracket for mounting acomponent in a headliner of a motor vehicle includes a collapsible crashbox which includes at least one collapsible level orientedconcentrically with respect to a supporting frame. At least one level ofthe crash box absorbs the impact along the longitudinal axis of thecrash box by collapsing against a layer of sheet metal of the motorvehicle. The component such as a coat hook has a clip for retaining andsecuring the component within the sheet metal of the vehicle. The crashbox farther comprises laterally spaced recesses for receiving tabs onthe corresponding component. During a sufficient impact, the clip willmove out of engagement with the sheet metal of the motor vehicle tofurther absorb the impact and promote passenger safety. In a secondembodiment of the invention, the crash box has resilient legs to retainthe crash box mounted to the sheet metal of the motor vehicle in theevent that the component is removed from the vehicle.

More specifically, the invention provides an energy dissipation assemblyfor dissipating energy between a vehicle component and a vehicle sheetmetal member. The assembly includes a collapsible crash box forming acentral aperture therethrough for receiving the vehicle component. Thecollapsible crash box includes a plurality of collapsible levelsoriented concentrically with respect to the central aperture. Anuppermost one of the levels is positioned to abut against the sheetmetal member and a lowermost one of the levels is positioned to abutagainst the component. A sufficient impact against the component causescollapse of the plurality of levels between the component and the sheetmetal member, thereby dissipating energy of the impact.

Accordingly, an object of the invention is to provide a collapsiblecrash box for dissipating energy between a vehicle component and a sheetmetal member, such as between a coat hook and a vehicle roof.

A further object of the invention is to provide a collapsible crash boxfor dissipating energy between a vehicle component and a vehicle roof,wherein the crash box provides sufficient stability, load bearing andcosmetic characteristics desired in such an application.

Other objects, features, and advantages of the invention will beapparent from the ensuing description in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of a crash boxcomponent holder for a motor vehicle with a headliner of the motorvehicle in phantom lines for clarity;

FIG. 2 is a sectional side view of the crash box component holder ofFIG. 1;

FIG. 3 is a side sectional view showing the crash box component holderof FIGS. 1 and 2 after impact due to, for example, a motor vehicleaccident;

FIG. 4 is a perspective view of a crash box component holder of thepresent invention;

FIG. 5 is a perspective view of a second embodiment of the crash boxcomponent holder;

FIG. 6 is a side elevational view of a third embodiment of theinvention;

FIG. 7 shows an exploded perspective view of a fourth embodiment of theinvention; and

FIG. 8 shows a plan view of the energy dissipator shown in FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIG. 1, an accessory and crash box component holder assembly10 comprises a coat hook 14 secured by a crash box component holder 12,which may also be referred to as crash box 12, mounted within aheadliner 41 of a motor vehicle. The coat hook 14 comprises a base 20that sealingly abuts the headliner 41 in a cosmetically pleasing mannerand mounts downwardly depending legs 18 connected by a cross bar 16. Thecoat hook 14 further comprises a door 22, which is secured in a closedposition after assembly and which cannot be opened during normal use.The headliner 41 is shown in phantom lines in FIG. 1. The crash boxcomponent holder 12 is actually within the headliner 41 in an opening 66thereof.

As shown in greater detail in FIG. 4, the crash box component holder 12concentrically comprises a first rectangular level 26, a secondrectangular level 30, and a third rectangular level 34. The third level34 includes two small, laterally spaced recesses 56 and a largerectangular recess 28 on a front face 29 thereof. A flange 27 of thesecond level 30 extends into a center portion of the crash box 12. Theflange 27 is aligned with the recess 28 of the third level 34 and isoriented perpendicular thereto at the elevation of the second level 30.The crash box component holder forms a central aperture 33 for receivingthe coat hook 14. The first, second and third levels 26,30,34 arearranged concentrically about the central aperture. An alternativeembodiment of the crash box 12 is shown in FIG. 5 wherein the crash box12 comprises resilient legs 62 having tabs 64 that retain the crash boxwithin the sheet metal of the motor vehicle during assembly and permitremoval of a component such as the coat hook 14.

The headliner 41 of the motor vehicle comprises an outer fabric or vinyllayer 40 and a layer batting 42. The batting 42 abuts a sheet metal 44which forms a part of the vehicle frame. As shown in FIG. 2, the coathook 14 further comprises a clip 24, which secures the coat hook andcrash box assembly 10 within the headliner 41. The clip 24 comprises afirst arm 60 and a second arm 46 joined by a U-shaped portion 47. Thefirst arm 60 further comprises a recess 50, which rigidly engages thesheet metal 44. The second arm 46 comprises a narrow end portion 58separated from the remainder of the second arm 46 by a tab 48 whichrigidly secures the second arm 46 to the sheet metal 44. The clip 24 ischosen such that the arms 60 and 46 must be moved closer with respect toeach other to be inserted into a hole in the sheet metal 44 andtherefore exert a spring force outwardly to rigidly retain the assembly10 within the headliner 41. The clip 24 is fully disclosed in U.S. Pat.No. 5,662,375 which is incorporated herein by reference. As illustratedin FIG. 2, the headliner opening 66 is shaped to follow the contour ofthe outer surface 34 of the crash box 12.

The coat hook 14 further comprises locking tabs 54 that are received inthe recesses 56 of the crash box 12 and a boss 39 that abuts the flange27 within the recess 28 of the crash box 12 that cooperate to stabilizethe coat hook 14 when the coat hook is mounted to the crash box 12. The.door 22 of the coat hook 14 mounts resilient legs 36 having tabs 38,which combine to secure the door 22 in a closed position in lockingengagement with the base 20 of the coat hook 14.

If a motor vehicle accident or other unexpected occurrence causes apassenger's head, for example, or other object to strike the coat hook14 with a sufficient upward force, the crash box 12 will absorb theimpact and promote passenger safety by sequentially collapsing thelevels 26,30, and 34 with respect to each other. As best shown in FIG.2, the third (or lowermost) level 34 is not supported by the secondlevel 30 against a sufficient vertical force, which, in turn, is notsupported by the first (or uppermost) level 26 against a sufficientvertical force.

The result of a sufficient impact is illustrated in FIG. 3 where thethird level 34 has collapsed into the second level 30 and the secondlevel 30 has, in turn, collapsed into the first level 26. A furtherresult of the impact is that the clip 24 disengages from the sheet metal44 and moves upwardly thereof. This feature has the effect that the coathook 14 may be able to be reused while the crash box 12, which hasabsorbed the impact, will need to be replaced.

It should be evident to one of skill in the art that the conceptembodied by the crash box 12 can support any type of component for theheadliner 41 or other part of the motor vehicle. It is theimpact-absorbing and deformation characteristics of the crash box 12that present the most important part of the invention. It is consideredthat any desirable impact-absorbing and deformation characteristics maybe attained through appropriate choice of material and manufacturingtechnique. FIG. 2 shows the crash box spaced away from the sheet metalmember. Spacing the crash box away from the coat hook would be anobvious variant of this structure.

The choice of the disclosed rectangular shape of the concentric levels26,30, and 34 of the crash box 12 are merely preferences and it isconsidered that any suitable shape including but not limited to circlesand triangles may be used. The disclosed number of concentric levels mayalso be increased and decreased to suit a particular application.Whereas the crash box has been shown with three crushable levels, it iswithin the scope of the invention to employ less than three levels, forexample, one or two levels, or more than three levels within the scopeof the invention.

Further, the coat hook 14 and the use of the clip 24 to secure thecomponent to the sheet metal 44 of the vehicle are merely preferencesand those skilled in the art may choose to employ the crash boxtechnology with other components and other securing means. Further, thedisclosed method of securing the coat hook 14 to the crash box 12 bymeans of the boss 39 of the coat hook 14 abutting the flange 27 of thecrash box 12 and the tab 54 of the coat hook 14 engaging the recess 56of the crash box 12 are preferred arrangements and any suitable methodof securing the component to the crash box 12 can be used.

The crash box 12 can also be used to mount the components to theheadliner before the headliner is installed into the vehicle.

Reference is now made to FIG. 6 in which like numerals have been used todescribe like parts. The crash box 12 has several wings or ears 32 whichare integrally formed with the box 12. These wings or ears 32 extendlaterally of the lower end of the first level 26 above the headliner 41to retain the crash box 12 and the coat hook 14 on the headliner 41before the headliner is installed in the vehicle.

Referring to FIGS. 7 and 8, a fourth embodiment of the invention isshown. As illustrated, an overhead component such as a grab handle 70 isattached to a metal clip 72 by a bolt 74, and is thereby secured to thesheet metal 76 of a vehicle. A headliner 78 is positioned between thegrab handle 70 and the sheet metal 76. The headliner 78 includes anaperture 80 formed therein which receives an energy dissipator 82. Theenergy dissipator 82 includes a hole 84 for receiving the bolt 74. Also,the energy dissipator 82 includes a plurality of deformable spikes 86which are operative to dissipate energy during an impact.

The spikes 86 are preferably made of plastic or reinforced plastic, andare configured to break or deform when subject to a compressivelengthwise force during impact to absorb impact energy.

Specifically, the spikes 86 would engage against the front face 88 ofthe metal clip 72 as the energy dissipator 82 recedes toward the sheetmetal 76 in a high energy impact.

The spikes 86 may be optimally sized for desired energy dissipationcharacteristics. This component is lightweight and inexpensive tomanufacture, and may reduce the need for further head impact foam orother countermeasures in the vehicle.

Reasonable variation and modification are possible within the spirit ofthe foregoing specification and drawings without departing from thescope of the invention as defined in the appended claims.

What is claimed is:
 1. An energy dissipation assembly for dissipatingenergy between a vehicle component and a vehicle sheet metal member, theassembly comprising: a collapsible crash box forming a central aperturetherethrough for receiving the vehicle component, said collapsible crashbox including a plurality of collapsible levels oriented concentricallywith respect to the central aperture; wherein an uppermost one of saidlevels is positioned to abut against the sheet metal member and alowermost one of said levels is positioned to abut against thecomponent, such that a sufficient impact against the component causescollapse of the plurality of levels between the component and the sheetmetal member, thereby dissipating energy of the impact, said collapsiblelevels being sequentially larger from one of the uppermost and lowermostlevels to the other of the uppermost and lowermost levels to facilitatesaid collapse, and said crash box being spaced away from at least one ofthe sheet metal member and the component prior to movement upon saidimpact such that the crash box contacts both the sheet metal member andthe component only during said impact; and wherein the componentincludes a clip for retaining and securing the component within thesheet metal member, said clip being disengagable from the sheet metalmember during said sufficient impact to allow collapse of the pluralityof levels.
 2. The assembly of claim 1, wherein the component comprises acoat hook and the sheet metal member comprises a vehicle roof.
 3. Theassembly of claim 1, wherein the component includes a clip for retainingand securing the component within the sheet metal member, said clipbeing disengagable from the sheet metal member during said sufficientimpact to allow collapse of the plurality of levels.
 4. The assembly ofclaim 1, wherein said plurality of levels are formed in a steppedconfiguration.
 5. The assembly of claim 1, wherein the crash boxcomprises resilient legs to retain the crash box to the sheet metalmember when the component is removed.
 6. The assembly of claim 1,wherein the crash box includes at least one ear extending outwardly fromsaid uppermost one of the levels to-retin the crash box on a headlinerbefore the headliner is installed in a vehicle.
 7. The assembly of claim1, wherein said plurality of collapsible levels comprise rectangularsteps.
 8. A vehicle headliner assembly attachable to a vehicle sheetmetal member, the assembly comprising: a headliner having an openingformed therethrough; a vehicle component positioned within the openingand for attachment to the sheet metal member; a collapsible crash boxforming a central aperture therethrough receiving the vehicle component,said collapsible crash box including a plurality of collapsible levelsoriented concentrically with respect to the central aperture, wherein anuppermost one of said levels is positioned to abut against the sheetmetal member and a lowermost one of said levels is positioned to abutagainst the component, such that a sufficient impact against thecomponent causes collapse of the plurality of levels between thecomponent and the sheet metal member, thereby dissipating energy of theimpact, and said crash box being spaced away from at least one of thesheet metal member and the component prior to movement during saidimpact such that the crash box contacts both the sheet metal member andthe component only during said impact, and wherein the crash boxcomprises resilient legs to retain the crash box to the sheet metalmember when the component is removed.
 9. The assembly of claim 8,wherein the component comprises a coat hook.
 10. The assembly of claim8, wherein the component includes a clip for retaining and securing thecomponent within an aperture formed in the sheet metal member, said clipbeing disengagable from the sheet metal member during said sufficientimpact to allow collapse of the plurality of levels.
 11. The assembly ofclaim 8, wherein said plurality of levels are formed in a steppedconfiguration.
 12. The assembly of claim 8, wherein the crash boxcomprises resilient legs to retain the crash box to the sheet metalmember when the component is removed.
 13. The assembly of claim 8,wherein the crash box includes at least one ear extending outwardly fromsaid uppermost one of the levels to retain the crash box on theheadliner before the headliner is attached to the sheet metal member.14. The assembly of claim 8, wherein said plurality of collapsiblelevels comprise rectangular steps.
 15. An energy dissipation assemblyfor dissipating energy between a vehicle coat hook and a vehicle sheetmetal member, the assembly comprising: a collapsible crash box forming acentral aperture therethrough for receiving the coat hook, saidcollapsible crash box including a plurality of collapsible levelsoriented concentrically with respect to the central aperture; andwherein an uppermost one of said levels is positioned to abut againstthe sheet metal member and a lowermost one of said levels is positionedto abut against the coat hook, such that a sufficient impact against thecoat hook causes collapse of the plurality of levels between the coathook and the sheet metal member, thereby dissipating energy of theimpact, and said crash box being spaced away from at least one of thesheet metal member and the coat hook prior to movement during saidimpact such that the crash box contacts both the sheet metal member andthe coat hook only during said impact, and wherein the crash boxincludes at least one ear extending outwardly from said uppermost one ofthe levels to retain the crash box on a headliner before the headlineris attached to the sheet metal member.
 16. The assembly of claim 15,wherein said crash box comprises a plastic component.